Slide fastener tape with molded zipper teeth and methods of making same

ABSTRACT

A molded-teeth slide fastener tape for use in a slide fastener assembly includes a woven portion and a plurality of resin-based teeth. The woven portion includes a cord arranged along an edge thereof and a plurality of spaced-apart perforations, disposed adjacent to the cord, which pass completely through the woven portion. Each of the plurality of resin-based teeth is integrally molded to the woven portion along the cord. Each molded tooth encompasses at least a portion of at least one of the spaced-apart perforations so that each molded tooth extends through the at least one of the spaced-apart perforations and fully around a cross-sectional shape of the cord.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a U.S. nonprovisional patent application of,and claims priority under 35 U.S.C. §119(e) to, U.S. provisional patentapplication Ser. No. 62/310,754, filed Mar. 20, 2016, and entitled,“SLIDE FASTENER,” which provisional patent application is incorporatedby reference herein in its entirety.

COPYRIGHT STATEMENT

All of the material in this patent document is subject to copyrightprotection under the copyright laws of the United States and othercountries. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosure,as it appears in official governmental records but, otherwise, all othercopyright rights whatsoever are reserved.

BACKGROUND OF THE PRESENT INVENTION

Field of the Present Invention

The present invention relates generally to slide fastener tapes, and, inparticular, to a strong and durable slide fastener tape, utilizingmolded zipper teeth, that exhibits enhanced resistance to lateralpulling forces.

Background

Slide fasteners (i.e., zippers) generally fall within one of threecategories: metal teeth zippers; coil-type zippers; and molded-teethzippers. Each category of zippers exhibits different physical andaesthetic aspects that make one zipper type preferable over others forcertain applications.

Metal teeth zippers were among the first commercially successfulzippers. The teeth of such zippers are formed by crimpingspecially-shaped pieces of metal wire around the beaded edge (i.e., thecord) of fabric slide fastener tapes. Metal teeth zippers have thegeneral appearance of a strong, durable zipper (due at least in part tothe use of metal teeth). However, in many cases, metal teeth are easilydamaged or inadvertently removed from the slide fastener tape, therebyrendering the zipper unusable. Furthermore, metal zipper teeth are proneto corrosion, which has a negative impact on the long-term durabilityand quality of the zipper. As a general proposition, manufacturing costsof metal teeth zipper vary based on the availability and cost ofhigh-quality metal wire.

Coil-type zippers are generally acknowledged as being very strongzippers. The “teeth” of coil-type zippers are formed by twisting (i.e.,coiling) polyester filament. The coiled filament is sewn to the cord ofthe slide fastener tape, and a portion of the coiled filament isflattened to form a “tooth.” By firmly attaching polyester coiledfilaments to the cord, coil-type zippers are not only quite strong butare generally impervious to corrosion. Furthermore, coil-type zippershave the advantage of being dyeable to any desired color. However,despite their strength, incurring damage to even a single tooth alongthe length of the zipper has the potential to render the zipperpermanently inoperative.

The teeth of a molded zipper are formed by closing a multi-part moldaround the slide fastener tapes and injecting a thermoplastic resin intothe mold. Once the resin cools and hardens, the resultant molded teethare very durable. Resins selected for use in manufacturing molded-teethzippers usually exhibit high stiffness and low friction. Furthermore,the resin can be expected to display dimensional stability across a widerange of use conditions. However, the zipper itself is only as strong asthe mechanism by which the molded teeth are held in place along the cordof the slide fastener tape. If a sufficient lateral pulling force isapplied (such as a lateral force that pulls one row of interlockedmolded teeth away from the other row of interlocked teeth), molded teethcan be removed from the slide fastener tape, thereby rendering thezipper inoperative. Additionally, under high-temperature conditions, arisk exists that the resin used to form the teeth may soften to thepoint that teeth become deformed and, ultimately, removed from the slidefastener tape. Molded-teeth zippers are often used in large-scaleapplications where a larger zipper may be useful. However, due to thelarge size of the individual teeth in such zippers, a removed moldedtooth can represent a choking hazard for young children.

Accordingly, a need exists for a strong and durable slide fastener tape,utilizing molded zipper teeth, that exhibits enhanced resistance tolateral pulling forces. Furthermore, a need exists for a method ofassembling a slide fastener tape that facilitates an enhanced bondbetween the molded tooth and the cord of the slide fastener tape. Theseand other needs are addressed by one or more aspects of the presentinvention.

SUMMARY OF THE PRESENT INVENTION

Some exemplary embodiments of the present invention may overcome one ormore of the above disadvantages and other disadvantages not describedabove, but the present invention is not required to overcome anyparticular disadvantage described above, and some exemplary embodimentsof the present invention may not overcome any of the disadvantagesdescribed above.

Broadly defined, the present invention according to one aspect includesa molded-teeth slide fastener tape for use in a slide fastener assembly.The slide fastener tape includes a woven portion and a plurality ofresin-based teeth. The woven portion includes a cord arranged along anedge thereof and a plurality of spaced-apart perforations, disposedadjacent to the cord, which pass completely through the woven portion.Each of the plurality of resin-based teeth is integrally molded to thewoven portion along the cord. Each molded tooth encompasses at least aportion of at least one of the spaced-apart perforations so that eachmolded tooth extends through the at least one of the spaced-apartperforations and fully around a cross-sectional shape of the cord.

In a feature of this aspect, the spaced-apart perforations may be evenlyspaced from one another.

In another feature of this aspect, each of the perforations may have anelongated shape. In another feature of this aspect, each of theperforations may have a generally circular shape.

In another feature of this aspect, each molded tooth may fully encompassone of the plurality of spaced-apart perforations. In another feature ofthis aspect, each molded tooth may fully encompass only a singlerespective one of the plurality of spaced-apart perforations. In anotherfeature of this aspect, each molded tooth may fully encompass multipleones of the plurality of spaced-apart perforations.

Broadly defined, the present invention according to another aspectincludes a method of making a molded-teeth slide fastener tape. Themethod includes: weaving a slide fastener tape including a cord arrangedalong an edge thereof; forming a plurality of spaced-apart perforationsthrough the woven slide fastener tape adjacent to the cord; andintegrally molding a plurality of resin-based teeth to the woven slidefastener tape so that a resin forming each tooth fills at least aportion of at least one of the spaced-apart perforations and, thereby,extends fully around a cross-sectional shape of the cord.

In a feature of this aspect, forming the plurality of spaced-apartperforations may include puncturing the woven slide fastener tape with ahot needle perforator. In another feature of this aspect, forming theplurality of spaced-apart perforations may include punching through thewoven slide fastener tape with a mechanical punch.

In another feature of this aspect, forming the plurality of spaced-apartperforations may include, during the weaving step: stopping one or morefirst consecutive weft yarns short of the cord to establish a gap in theslide fastener tape; passing one or more second consecutive weft yarns,immediately adjacent to the one or more first consecutive weft yarns,fully to the cord to close the gap, the one or more first consecutiveweft yarns and the one or more second consecutive weft yarnsestablishing a weft yarn sequence; and repeating the weft yarn sequenceto form a pattern of perforations adjacent to the cord, each perforationcorresponding to one of the gaps established by the one or more firstconsecutive weft yarns of the weft yarn sequence.

In another feature of this aspect, the one or more first consecutiveweft yarns of the weft yarn sequence may include four consecutive weftyarns, and the one or more second consecutive weft yarns of the weftyarn sequence may include two consecutive weft yarns.

In other features of this aspect, a length dimension of each of theplurality of spaced-apart perforations may be defined by a quantity ofthe one or more first consecutive weft yarns of the weft yarn sequence;spacing between each of the plurality of spaced-apart perforations maybe defined by a quantity of the one or more second consecutive weftyarns of the weft yarn sequence; and/or a width of each of the pluralityof spaced-apart perforations may be defined by a distance by which theone or more first consecutive weft yarns are stopped short of the cord.

In another feature of this aspect, the method may further includeprecisely positioning the slide fastener tape relative to a moldingmachine so that a mold for each individual tooth fully encompasses onlya single respective one of the plurality of spaced-apart perforations.

In another feature of this aspect, the method may further includefurther comprising positioning the slide fastener tape relative to amolding machine so that a mold for each individual tooth fullyencompasses multiple ones of the plurality of spaced-apart perforations.In another feature of this aspect, the resin may be a thermoplasticresin.

In another feature of this aspect, the spaced-apart perforations may beevenly spaced from one another. In another feature of this aspect, eachof the spaced-apart perforations may have an elongated shape. In anotherfeature of this aspect, each of the spaced-apart perforations may have agenerally circular shape.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features, embodiments, and advantages of the present inventionwill become apparent from the following detailed description withreference to the drawings, wherein:

FIG. 1A is a diagrammatic front view of a portion of a conventionalmolded-teeth slide fastener tape;

FIG. 1B is a close-up diagrammatic front view of the conventionalmolded-teeth slide fastener tape of FIG. 1A;

FIG. 1C is a sectional diagrammatic view of the conventionalmolded-teeth slide fastener tape of FIG. 1B, taken along line 1C-1C;

FIG. 2 is a diagrammatic front view of a portion of a slide fastenertape, in accordance with one or more aspects of the present invention,having a series of elongated perforations formed adjacent to the cord;

FIG. 3A is a diagrammatic front view of a portion of a molded-teethslide fastener tape, in accordance with one or more aspects of thepresent invention, made using the slide fastener tape of FIG. 2 andshowing each tooth fully encompassing a single one of the elongatedperforations;

FIG. 3B is a close-up diagrammatic front view of the molded-teeth slidefastener tape of FIG. 3A;

FIG. 3C is a sectional diagrammatic view of the molded-teeth slidefastener tape of FIG. 3B, taken along line 3C-3C;

FIG. 4A is a diagrammatic front view of a portion of anothermolded-teeth slide fastener tape, in accordance with one or more aspectsof the present invention, made using the slide fastener tape of FIG. 2and showing each tooth encompassing a portion of at least one elongatedperforation;

FIG. 4B is a close-up diagrammatic front view of the molded-teeth slidefastener tape of FIG. 4A;

FIG. 4C is a sectional diagrammatic view of the molded-teeth slidefastener tape of FIG. 4B, taken along line 4C-4C;

FIG. 5 is a diagrammatic front view of a portion of another slidefastener tape, in accordance with one or more aspects of the presentinvention, having a series of small perforations formed adjacent to thecord;

FIG. 6A is a diagrammatic front view of a portion of anothermolded-teeth slide fastener tape, in accordance with one or more aspectsof the present invention, made using the slide fastener tape of FIG. 5and showing each tooth fully encompassing a plurality of the smallperforations;

FIG. 6B is a close-up diagrammatic front view of the molded-teeth slidefastener tape of FIG. 6A;

FIG. 6C is a sectional diagrammatic view of the molded-teeth slidefastener tape of FIG. 6B, taken along line 6C-6C;

FIG. 7 is a flowchart illustrating a method of making a molded-teethslide fastener tape in accordance with one or more aspects of thepresent invention; and

FIG. 8 is a close-up diagrammatic front view of another slide fastenertape, similar to that of FIG. 2, illustrating the formation ofperforations in the slide fastener tape using a weaving process.

DETAILED DESCRIPTION

As a preliminary matter, it will readily be understood by one havingordinary skill in the relevant art (“Ordinary Artisan”) that the presentinvention has broad utility and application. Furthermore, any embodimentdiscussed and identified as being “preferred” is considered to be partof a best mode contemplated for carrying out the present invention.Other embodiments also may be discussed for additional illustrativepurposes in providing a full and enabling disclosure of the presentinvention. As should be understood, any embodiment may incorporate onlyone or a plurality of the above-disclosed aspects of the invention andmay further incorporate only one or a plurality of the above-disclosedfeatures. Moreover, many embodiments, such as adaptations, variations,modifications, and equivalent arrangements, will be implicitly disclosedby the embodiments described herein and fall within the scope of thepresent invention.

Accordingly, while the present invention is described herein in detailin relation to one or more embodiments, it is to be understood that thisdisclosure is illustrative and exemplary of the present invention, andis made merely for the purposes of providing a full and enablingdisclosure of the present invention. The detailed disclosure herein ofone or more embodiments is not intended, nor is to be construed, tolimit the scope of patent protection afforded the present invention,which scope is to be defined by the claims and the equivalents thereof.It is not intended that the scope of patent protection afforded thepresent invention be defined by reading into any claim a limitationfound herein that does not explicitly appear in the claim itself.

Thus, for example, any sequence(s) and/or temporal order of steps ofvarious processes or methods that are described herein are illustrativeand not restrictive. Accordingly, it should be understood that, althoughsteps of various processes or methods may be shown and described asbeing in a sequence or temporal order, the steps of any such processesor methods are not limited to being carried out in any particularsequence or order, absent an indication otherwise. Indeed, the steps insuch processes or methods generally may be carried out in variousdifferent sequences and orders while still falling within the scope ofthe present invention. Accordingly, it is intended that the scope ofpatent protection afforded the present invention is to be defined by theappended claims rather than the description set forth herein.

Additionally, it is important to note that each term used herein refersto that which the Ordinary Artisan would understand such term to meanbased on the contextual use of such term herein. To the extent that themeaning of a term used herein—as understood by the Ordinary Artisanbased on the contextual use of such term—differs in any way from anyparticular dictionary definition of such term, it is intended that themeaning of the term as understood by the Ordinary Artisan shouldprevail.

Regarding applicability of 35 U.S.C. §112, ¶6, no claim element isintended to be read in accordance with this statutory provision unlessthe explicit phrase “means for” or “step for” is actually used in suchclaim element, whereupon this statutory provision is intended to applyin the interpretation of such claim element.

Furthermore, it is important to note that, as used herein, “a” and “an”each generally denotes “at least one,” but does not exclude a pluralityunless the contextual use dictates otherwise. Thus, reference to “apicnic basket having an apple” describes “a picnic basket having atleast one apple” as well as “a picnic basket having apples.” Incontrast, reference to “a picnic basket having a single apple” describes“a picnic basket having only one apple.”

When used herein to join a list of items, “or” denotes “at least one ofthe items,” but does not exclude a plurality of items of the list. Thus,reference to “a picnic basket having cheese or crackers” describes “apicnic basket having cheese without crackers,” “a picnic basket havingcrackers without cheese,” and “a picnic basket having both cheese andcrackers.” Finally, when used herein to join a list of items, “and”denotes “all of the items of the list.” Thus, reference to “a picnicbasket having cheese and crackers” describes “a picnic basket havingcheese, wherein the picnic basket further has crackers,” as well asdescribes “a picnic basket having crackers, wherein the picnic basketfurther has cheese.”

Referring now to the drawings, in which like numerals represent likecomponents throughout the several views, one or more preferredembodiments of the present invention are next described. The followingdescription of one or more preferred embodiment(s) is merely exemplaryin nature and is in no way intended to limit the invention, itsapplication, or uses.

FIG. 1A is a diagrammatic front view of a portion of a conventionalmolded-teeth slide fastener tape 100. FIGS. 1B and 1C are a close-updiagrammatic front view and a sectional diagrammatic view, respectively,of the conventional molded-teeth slide fastener tape 100 of FIG. 1A. Asshown in FIGS. 1A-1C, the conventional molded-teeth slide fastener tape100 includes a fabric tape 105 having a beaded edge, or cord 104,extending along an inner side thereof (i.e., the side that would facethe inner side of an opposing slide fastener tape in an assembled slidefastener). In many cases, the cord 104 is integrally formed as part ofthe slide fastener tape 105, usually via a weaving process.

As perhaps best seen in the sectional view of FIG. 1C, individual teeth102 are molded to the slide fastener tape along the cord 104. Eachindividual tooth 102 is formed, via a molding process, so that eachpinches or grips the cord 104 at top and bottom surfaces 107,108 of theslide fastener tape 105. It should be apparent that a sufficient lateralpulling force applied to the teeth 102 or the slide fastener tape 105can result in deformation of the tape 105 (i.e., stretching can make thetape thinner and, thereby, deform the cord 104). If the cord 104 becomesthinned or deformed, there is an increased likelihood that teeth 102could inadvertently be removed from the cord, thereby rendering theslide fastener inoperable. Furthermore, a lateral pulling force appliedto the teeth 102 carries the risk that one or more of the teeth can,themselves, become deformed (such as by the gripping ends 111,112 of theteeth 102 being pulled apart from one another), thereby facilitatinginadvertent removal of a tooth from the tape 105.

FIG. 2 is a diagrammatic front view of a portion of a slide fastenertape 205, in accordance with one or more aspects of the presentinvention, having a series of elongated perforations 220 formed adjacentto the cord 204. As shown in FIG. 2, the slide fastener tape 205 has abeaded edge, or cord 204, extending along an inner side thereof (i.e.,the side that would face the inner side of an opposing slide fastenertape in an assembled slide fastener). It is contemplated that the cord204 can be integrally formed as part of the slide fastener tape 205,usually via a weaving process.

As further shown in FIG. 2, the slide fastener tape 205 includes aseries of spaced-apart perforations 220 that extend along a length ofthe tape, adjacent to the cord 204. In one contemplated embodiment, theperforations 220 are evenly and uniformly spaced apart from one another.In other embodiments, the perforations 220 can be formed periodically,clustered together in groups, or otherwise, as might be required in aparticular end-use slide fastener assembly. It is contemplated thatperforations can be formed to have any desired size or shape, as mightbe preferred for a variety of different slide fastener assemblies. Inthe embodiment depicted in FIG. 2, the perforations 220 are formed aselongated, slotted openings.

As will be discussed in greater detail below, it is contemplated thatperforations 220 can be formed in the slide fastener tape 205 by avariety of different mechanisms, including, but not limited to, using amechanical punch, using a hot needle perforator or by forming theperforations via the weaving process itself.

FIG. 3A is a diagrammatic front view of a portion of a molded-teethslide fastener tape 200, in accordance with one or more aspects of thepresent invention, made using the slide fastener tape 205 of FIG. 2 andshowing each tooth 202 fully encompassing a single one of the elongatedperforations 220. FIGS. 3B and 3C are a close-up diagrammatic front viewand a sectional diagrammatic view, respectively, of the molded-teethslide fastener tape 200 of FIG. 3A. As shown in FIGS. 3A and 3B,individual teeth 202 are molded to the slide fastener tape 205 along thecord 204 to create one half of an interlocking slide fastener. Asperhaps best seen in FIG. 3B, the width of each tooth 202 is slightlylarger than the length of one of the evenly and uniformly spacedelongated perforations 220. Individual teeth 202 of the embodiment ofFIGS. 3A-3C are molded so that each tooth fully covers and encompasses arespective one of the elongated perforations 220. However, it should benoted that there is no requirement that each tooth fully encompass asingle perforation. As will be discussed in greater detail below, it isfurther contemplated that teeth can be molded to the tape so that eachtooth covers and encompasses only a portion of one of the perforations,that each tooth covers and encompasses at least a portion of multipleperforations, that each tooth fully covers and encompasses multipleperforations, or that each tooth fully covers and encompasses at leastone perforation and covers and encompasses portions of one or more otherperforations.

In accordance with the embodiment of FIGS. 3A-3C, teeth molding isaccomplished in such a way that each molded tooth 202 corresponds withand fully encompasses a single respective elongated perforation 220.During the molding process, resin that enters the mold for each tooth202 passes through and fills the respective elongated perforation 220.Once molding is complete, the resulting teeth 202 are integrally moldedto the tape 205, as perhaps best seen in the sectional view of FIG. 3C.Rather than just pinch or grip the cord 204, teeth 202 are formed withthe molding resin flowing through the tape 205 so that each toothextends fully around the cross-sectional shape of the cord 204. In thismanner, the molded-teeth slide fastener tape 200 exhibits enhancedstrength and durability and, in particular, is better conditioned towithstand a lateral pulling force. Furthermore, because each tooth 202passes through the slide fastener tape 205 via one of the elongatedperforations 220, teeth are more impervious to distortion and aregenerally incapable of being removed from the tape 205 unless the cord204 itself is severed.

FIG. 4A is a diagrammatic front view of a portion of anothermolded-teeth slide fastener tape 300, in accordance with one or moreaspects of the present invention, made using the slide fastener tape 205of FIG. 2 and showing each tooth 302 encompassing a portion of at leastone elongated perforation 220. FIGS. 4B and 4C are a close-updiagrammatic front view and a sectional diagrammatic view, respectively,of the molded-teeth slide fastener tape 300 of FIG. 4A. As shown inFIGS. 4A and 4B, individual teeth 302 are molded to the slide fastenertape 205 along the cord 204 to create one half of an interlocking slidefastener. The width of each tooth 302 is slightly larger than the lengthof one of the evenly and uniformly spaced elongated perforations 220.However, rather than each tooth fully encompassing a respective one ofthe elongated perforations (as in FIGS. 3A and 3B), each tooth 302molded to the slide fastener tape 205 of FIGS. 4A and 4B covers andencompasses a portion of at least one elongated perforation 220 orportions of multiple elongated perforations 220.

In accordance with the embodiment of FIGS. 4A-4C, teeth molding isaccomplished in such a way that each molded tooth 302 corresponds withand encompasses at least a portion of at least one elongated perforation220. During the molding process, resin that enters the mold for eachtooth 302 passes through and fills any portion of elongated perforations220 covered by the mold. Once molding is complete, the resulting teeth302 are integrally molded to the tape 205, as perhaps best seen in thesectional view of FIG. 4C. Rather than just pinch or grip the cord 204,teeth 302 are formed with the molding resin flowing through the tape 205so that each tooth extends fully around the cross-sectional shape of thecord 204. In this manner, the molded-teeth slide fastener tape 300exhibits enhanced strength and durability and, in particular, is betterconditioned to withstand a lateral pulling force. Furthermore, becauseeach tooth 302 passes through the slide fastener tape 205 via one ormore of the elongated perforations 220, teeth are more impervious todistortion and are generally incapable of being removed from the tape205 unless the cord 204 itself is severed.

FIG. 5 is a diagrammatic front view of a portion of another slidefastener tape 405, in accordance with one or more aspects of the presentinvention, having a series of small perforations 420 formed adjacent tothe cord 404. The slide fastener tape 405 has a beaded edge, or cord404, extending along an inner side thereof (i.e., the side that wouldface the inner side of an opposing slide fastener tape in an assembledslide fastener). It is contemplated that the cord 404 can be integrallyformed as part of the slide fastener tape 405, usually via a weavingprocess.

Just as with the embodiments described in connection with FIG. 2, theslide fastener tape 405 of FIG. 5 includes a series of spaced-apartperforations 420 that extend along a length of the tape, adjacent to thecord 404. In one contemplated embodiment, the perforations 420 areevenly and uniformly spaced apart from one another. In otherembodiments, the perforations 420 can be formed periodically, clusteredtogether in groups, or otherwise, as might be required in a particularend-use slide fastener assembly. It is contemplated that perforationscan be formed to have any desired size or shape, as might be preferredfor a variety of different slide fastener assemblies. In the embodimentdepicted in FIG. 5, the perforations 420 are formed as small, roundedopenings.

FIG. 6A is a diagrammatic front view of a portion of anothermolded-teeth slide fastener tape 400, in accordance with one or moreaspects of the present invention, made using the slide fastener tape 405of FIG. 5 and showing each tooth 402 fully encompassing a plurality ofthe small perforations 420. FIGS. 6B and 6C are a close-up diagrammaticfront view and a sectional diagrammatic view, respectively, of themolded-teeth slide fastener tape 400 of FIG. 6A. As shown in FIGS. 6Aand 6B, individual teeth 402 are molded to the slide fastener tape 405along the cord 404 to create one half of an interlocking slide fastener.As perhaps best seen in FIG. 6B, each tooth 402 fully covers andencompasses multiple small perforations 420 of the slide fastener tape405.

In accordance with the embodiment of FIGS. 6A-6C, teeth molding isaccomplished in such a way that each molded tooth 402 corresponds withand encompasses multiple small perforations 420. During the moldingprocess, resin that enters the mold for each tooth 402 passes throughand fills all small perforations 420 covered by the mold. Once moldingis complete, the resulting teeth 402 are integrally molded to the tape405, as perhaps best seen in the sectional view of FIG. 6C. Rather thanjust pinch or grip the cord 404, teeth 402 are formed with the moldingresin flowing through the tape 405 so that each tooth extends fullyaround the cross-sectional shape of the cord 404. In this manner, themolded-teeth slide fastener tape 400 exhibits enhanced strength anddurability and, in particular, is better conditioned to withstand alateral pulling force. Furthermore, because each tooth 402 passesthrough the slide fastener tape 405 via multiple small perforations,teeth are more impervious to distortion and are generally incapable ofbeing removed from the tape 405 unless the cord 404 itself is severed.

FIG. 7 is a flowchart illustrating a method of making a molded-teethslide fastener tape in accordance with one or more aspects of thepresent invention. It is contemplated that methods, as described herein,can be used to create slide fastener tapes and finished slide fastenerswith molded zipper teeth in accordance with any of thepreviously-described embodiments of FIGS. 3A-3C, FIGS. 4A-4C and FIGS.6A-6C.

One contemplated method 500 involves weaving the tape, at step 510, insuch a way that the beaded edge is formed at one side thereof. Once thetape is woven, a series of perforations can be formed adjacent thebeaded edge, at step 520, by any of a variety of different mechanisms.In one contemplated embodiment, perforations are formed using amechanical punch to remove part of the woven slide fastener tape,thereby defining an opening that passes completely through the tape. Inanother contemplated embodiment, perforations are formed by using a hotneedle perforator to create punctures in the tape. The hot needleperforator can be particularly useful to create perforations withoutfraying along the edges of the formed perforation. Though a mechanicalpunch and hot needle perforator can each be used to create perforationsof any desired dimensions, it is contemplated that a hot needleperforator can be used to create relatively small, rounded perforations420 effectively, as described in connection with FIGS. 6A-6C, while amechanical punch may be well-suited to create elongated perforations220,320, as described in connection with FIGS. 3A-3C and FIGS. 4A-4C.Additionally, as described in greater detail below in connection withFIG. 8, it is further contemplated that, instead of using a mechanicalpunch or hot needle perforator, perforations can be formed in the slidefastener tape via the weaving process itself.

Once perforations have been formed in the slide fastener tape, the tapeis ready for the teeth molding process at step 530. A molding machine isused to receive the slide fastener tape along its beaded edge. In onecontemplated embodiment, the slide fastener tape is precisely arrangedin the molding machine so that each individual molded tooth fully coversand encompasses a respective one of the perforations, such as in theembodiment of FIGS. 3A-3C. However, as described above, there is norequirement that each tooth fully encompass a single perforation. Inanother contemplated embodiment, the slide fastener tape is arranged inthe molding machine (without precise arrangement) to ensure that eachindividual molded tooth covers and encompasses at least a portion of atleast one of the perforations, such as in the embodiment of FIGS. 4A-4C.In still another contemplated embodiment, the slide fastener tape isarranged in the molding machine so that each individual molded toothfully covers and encompasses multiple perforations. In this latterembodiment, small perforation size, such as in the embodiment of FIGS.6A-6C, can help enable each molded tooth to fully encompass multipleperforations. Here, again, precise arrangement of the slide fastenertape is not required, as the molded teeth are sufficiently largerelative to the pitch of the small perforations to ensure that eachtooth fully encompasses multiple perforations.

In each of the above-described embodiments, resin is injected into themold to form zipper teeth. Although various types of resins can be used,it is contemplated that the resin is preferably a thermoplastic resin.In at least one embodiment, DELRIN® resin, which is manufactured by E.I.du Pont de Nemours and Company, is selected as the resin used formolding the zipper teeth. As the resin fills the mold, resin passesthrough and fills any perforation or portion thereof that is covered bythe mold. Once molding is complete, the resulting teeth are integrallymolded to the tape (with each individual molded tooth extending throughat least a portion of one of the perforations and, thus, fully aroundthe cross-sectional shape of the cord), thereby yielding a molded-teethslide fastener tape that exhibits increased strength and durabilityagainst a lateral pulling force.

The molded-teeth slide fastener tape can then be processed further, atstep 540, as part of assembling a slide fastener. Usually, themolded-teeth slide fastener tape is paired with another such tape inorder to assemble a finished slide fastener. In this regard, it iscontemplated that various finishing steps can be executed with respectto one or both tapes that include, but are not limited to, adding a pinand box assembly to one end of the pair of tapes, adding one or more topstops to the other end of the pair of tapes, and adding a slider body toone of the row of zipper teeth for bringing the molded teeth from onetape into interlocking arrangement with the molded teeth of the othertape. Furthermore, it is contemplated that the molded-teeth slidefastener tapes can be implemented (such as by sewing or adhesion) tovarious end-use products, such as clothing, garments, luggage, coversfor bedding accessories and the like. The molded-teeth slide fastenertapes can impart such articles with a finished and functional slidefastener that combines corrosion-proof construction and an attractiveappearance with the enhanced strength and durability arising from theability to withstand lateral pulling forces (without rendering the slidefastener inoperative due to loss of or damage to individual moldedzipper teeth).

FIG. 8 is a close-up diagrammatic front view of another slide fastenertape 605, similar to that of FIG. 2, illustrating the formation ofperforations 620 in the slide fastener tape using a weaving process. Inat least some embodiments, perforations 620 of any desired shape or sizecan be formed in the slide fastener tape 605 as part of the weavingprocess. Transverse yarns, or weft yarns, typically extend fully acrossthe woven tape 605, including the cord 604 that is integrally formed(usually by the weaving process) along one side thereof. However, insome embodiments, it is contemplated that certain weft yarns can bestopped short of the cord 604 by a small margin rather than pass all theway to and/or over the cord 604. By stopping certain weft yarns short ofthe cord 604 during the weaving process, a perforation 620 can be formedin the slide fastener tape 605 adjacent the cord 604 at the locationwhere the weft yarns would otherwise pass.

A pattern of perforations 620 can be formed in the slide fastener tape605 by selecting which particular weft yarns are stopped short of thecord 604 and which particular weft yarns are passed through to thebeaded edge of the woven tape 605. As shown in one contemplatedembodiment, depicted in FIG. 8, four consecutive weft yarns 630 a, 630b, 630 c, 630 d are stopped short of the cord 604 during the weavingprocess, thereby defining a perforation 620 adjacent the cord 604 wherethe yarns would otherwise pass. The four consecutive weft yarns 630 a,630 b, 630 c, 630 d that are stopped short of the cord 604 are followedby two consecutive weft yarns 630 e, 630 f that pass all the way toand/or over the cord 604. This sequence (i.e., four consecutive yarnsstopped short and then two consecutive yarns that pass to the edge) canbe repeated in succession to define a pattern of evenly and uniformlyspaced elongated perforations 620 along the length of the tape.

The quantity of consecutive yarns 630 a, 630 b, 630 c, 630 d that arestopped short of the cord 604 defines the length dimension of the formedperforation 620, and the quantity of consecutive yarns 630 e, 630 f thatpass all the way to and/or over the cord 604 defines the spacing betweenformed perforations 620. As should be clear, length dimensions andspacing of the perforations 620 can thus be varied simply by adjustingthe respective quantities of consecutive weft yarns in the sequence. Themargin by which the yarns 630 a, 630 b, 630 c, 630 d stop short of thecord 604 defines the width dimension of the formed perforation 620. Assuch, the width dimension of the perforations 620 can be varied byadjusting the location where weft yarns 630 a, 630 b, 630 c, 630 d arestopped short relative to the cord 604.

It is contemplated that the sequence can be selected to coordinate withthe dimensions of the teeth to be molded to the slide fastener tape. Inone contemplated embodiment, the sequence is selected so that eachperforation has a generally elongated shape, whereby each molded tootheither fully encompasses a respective one of the elongated perforations(as in FIGS. 3A-3C) or encompasses at least a portion of one or more ofthe elongated perforations (as in FIGS. 4A-4C). In another contemplatedembodiment, the sequence is selected so that each perforation is smalland rounded (or circular), whereby each molded tooth fully encompassesmultiple perforations (as in FIGS. 6A-6C).

Based on the foregoing information, it will be readily understood bythose persons skilled in the art that the present invention issusceptible of broad utility and application. Many embodiments andadaptations of the present invention other than those specificallydescribed herein, as well as many variations, modifications, andequivalent arrangements, will be apparent from or reasonably suggestedby the present invention and the foregoing descriptions thereof, withoutdeparting from the substance or scope of the present invention.

Accordingly, while the present invention has been described herein indetail in relation to one or more preferred embodiments, it is to beunderstood that this disclosure is only illustrative and exemplary ofthe present invention and is made merely for the purpose of providing afull and enabling disclosure of the invention. The foregoing disclosureis not intended to be construed to limit the present invention orotherwise exclude any such other embodiments, adaptations, variations,modifications or equivalent arrangements; the present invention beinglimited only by the claims appended hereto and the equivalents thereof.

What is claimed is:
 1. A molded-teeth slide fastener tape for use in a slide fastener assembly comprising: a woven portion including a cord arranged along an edge thereof and a plurality of spaced-apart perforations, disposed adjacent to the cord, which pass completely through the woven portion; and a plurality of resin-based teeth integrally molded to the woven portion along the cord; wherein each molded tooth encompasses at least a portion of at least one of the spaced-apart perforations so that each molded tooth extends through the at least one of the spaced-apart perforations and fully around a cross-sectional shape of the cord.
 2. The molded-teeth slide fastener tape of claim 1, wherein the spaced-apart perforations are evenly spaced from one another.
 3. The molded-teeth slide fastener tape of claim 1, wherein each of the perforations has an elongated shape.
 4. The molded-teeth slide fastener tape of claim 1, wherein each of the perforations has a generally circular shape.
 5. The molded-teeth slide fastener tape of claim 1, wherein each molded tooth fully encompasses one of the plurality of spaced-apart perforations.
 6. The molded-teeth slide fastener tape of claim 5, wherein each molded tooth fully encompasses only a single respective one of the plurality of spaced-apart perforations.
 7. The molded-teeth slide fastener tape of claim 1, wherein each molded tooth fully encompasses multiple ones of the plurality of spaced-apart perforations.
 8. A method of making a molded-teeth slide fastener tape comprising: weaving a slide fastener tape including a cord arranged along an edge thereof; forming a plurality of spaced-apart perforations through the woven slide fastener tape adjacent to the cord; and integrally molding a plurality of resin-based teeth to the woven slide fastener tape so that a resin forming each tooth fills at least a portion of at least one of the spaced-apart perforations and, thereby, extends fully around a cross-sectional shape of the cord.
 9. The method of claim 8, wherein forming the plurality of spaced-apart perforations includes puncturing the woven slide fastener tape with a hot needle perforator.
 10. The method of claim 8, wherein forming the plurality of spaced-apart perforations includes punching through the woven slide fastener tape with a mechanical punch.
 11. The method of claim 8, wherein forming the plurality of spaced-apart perforations includes, during the weaving step: stopping one or more first consecutive weft yarns short of the cord to establish a gap in the slide fastener tape; passing one or more second consecutive weft yarns, immediately adjacent to the one or more first consecutive weft yarns, fully to the cord to close the gap, the one or more first consecutive weft yarns and the one or more second consecutive weft yarns establishing a weft yarn sequence; and repeating the weft yarn sequence to form a pattern of perforations adjacent to the cord, each perforation corresponding to one of the gaps established by the one or more first consecutive weft yarns of the weft yarn sequence.
 12. The method of claim 11, wherein: the one or more first consecutive weft yarns of the weft yarn sequence includes four consecutive weft yarns; and the one or more second consecutive weft yarns of the weft yarn sequence includes two consecutive weft yarns.
 13. The method of claim 11, wherein a length dimension of each of the plurality of spaced-apart perforations is defined by a quantity of the one or more first consecutive weft yarns of the weft yarn sequence.
 14. The method of claim 11, wherein spacing between each of the plurality of spaced-apart perforations is defined by a quantity of the one or more second consecutive weft yarns of the weft yarn sequence.
 15. The method of claim 11, wherein a width of each of the plurality of spaced-apart perforations is defined by a distance by which the one or more first consecutive weft yarns are stopped short of the cord.
 16. The method of claim 8, further comprising precisely positioning the slide fastener tape relative to a molding machine so that a mold for each individual tooth fully encompasses only a single respective one of the plurality of spaced-apart perforations.
 17. The method of claim 8, further comprising positioning the slide fastener tape relative to a molding machine so that a mold for each individual tooth fully encompasses multiple ones of the plurality of spaced-apart perforations.
 18. The method of claim 8, wherein the resin is a thermoplastic resin.
 19. The method of claim 8, wherein the spaced-apart perforations are evenly spaced from one another.
 20. The method of claim 8, wherein each of the spaced-apart perforations has an elongated shape.
 21. The method of claim 8, wherein each of the spaced-apart perforations has a generally circular shape. 